Step 1. Build the deck sub-structure
Build the deck sub-structure using traditional load-bearing materials, such as pressure treated lumber or steel (see Figure 1). NEVER use AURORA Decking System materials for joists, posts, beams, studs, columns, or stringers. The deck sub-structure should have joists with standard 16 inch centers. Individuals may wish to consult instructional resources (books or videos) to learn the best methods for constructing a safe and sturdy deck foundation.
Step 2. Install starter channel
Starter channel should be secured to the deck substructure along any edge of the deck surface that will abut a vertical surface (such as the outside wall of a home). Place the flat side of the starter channel against the vertical surface. Use anchor biscuits to push the starter channel snug against the vertical surface. Use a 1½" deck screw to secure the anchor biscuit to the deck substructure (see Figure 2).
Step 3. Install deck boards
Slide the first deck board under the top of the starter channel. Push the deck board toward the anchor biscuit until the anchor biscuit arm fills the slot along the deck board. Insert anchor biscuits into the slot along the exposed side of the deck board above each joist. Tap anchor biscuits into the slot using a rubber mallet to ensure a snug fit. Secure the anchor biscuits to the joists using 1½" deck screws (see Figure 3). Slide the slot in the next deck board around the exposed anchor biscuits. Insert anchor biscuits into the exposed slot of the new deck board above the joists. Secure the anchor biscuits to joists with 1½" deck screws. Continue sliding deck board slots around exposed anchor biscuits, and inserting and securing new anchor biscuits, until the entire substructure is covered.
Deck surfaces longer than 20' will require butting deck boards. The seam between butted deck boards should lie directly above a joist. Do not use a biscuit at this seam, but center the seam over the joist, and toenail each deckboard down into the joist. Use deckscrews at least 2.5" in length (see Figure 4). To prevent seams from opening, do not have both ends of a deckboard butted to other boards..
Step 4. Finish the exposed deck edges
The base plates of deck board must be even with the outside of the rim joists. Use a chalk line to mark the deck boards above the outside edge of the rim joists. Use a circular saw with a fine-tooth blade or abrasive disk to trim the deck boards along the chalk line (see Figure 5).
Step 5. Insert end clamp strips lengthwise into the slot along the exposed side of outer deck boards
A lower interior wall may need to be removed with a circular saw if the outer deck board has been ripped to size. Cut additional clamp strips into 1" pieces. Insert a 1" end clamp piece into the lower center chamber of every third deck board end (see Figure 6).
Step 6. Use anchor biscuits to secure end clamp strips and end clamp pieces to rim joists
Drive a 1½ " deck screw through the slot in the anchor biscuit and through the end clamp into the rim joist. Use one anchor biscuit every 16" along the end clamp strips, and one anchor biscuit for every 1" end clamp piece along the end (see Figure 7).
Step 7. Snap finishing trim to anchor biscuits to conceal the exposed edges and sides of deck boards
Finishing trim may be miter cut, or notched and bent, to accommodate deck corners (see Figure 8).
Step 8. Slide fascia under the finishing trim and around anchor biscuits to conceal rim joists
Slide anchor biscuits into the slot along the bottom of the fascia. Place one biscuit every 16" along the bottom of he fascia. Secure each anchor biscuit to the rim joist by driving a 1½ " deck screw through the slot (see Figure 9).
Step 9. Slide the next fascia around the exposed arms of the lower anchor biscuits
Slide new anchor biscuits into the slot along the bottom of the fascia every 16". Secure each anchor biscuit to the rim joist with a 1½" deck screw. Continue adding fascia and anchor biscuits until the desired portion of the sub-structure is concealed. Miter cut, or notch and bend, fascia and finishing trim for deck corners (see Figure 10).
Step by Step installation Guide for Steps:
Step 1. Use stringers when building steps
Stringers should have a rise of 6 to 7", with a tread depth of 12". Use end clamps, anchor biscuits, and finishing trim to finish the outer edge of the stair tread (as you would for finishing exposed deck edges). Rip fascia to be 1½" smaller than the rise (e.g. fascia for stringers with a 6" rise should be ripped to 4½" in width). Slide the fascia under the finishing trim and around the anchor biscuits with the ripped side facing down. Secure the bottom of the fascia with a deck screw driven through the fascia into the stringer (see Figure 11).
Step 2. Trim one side of anchor biscuits for insides of stringer treads
Secure anchor biscuits to stringers with deck screws. Add deck boards and anchor biscuits to cover the entire tread. If a partial deck board (ripped lengthwise) is required to cover a stringer tread, that board should be anchored along the interior tread corner.
Step 3. Trim deck board to be flush with the outsides of outer stringers
Fascia and finishing trim may be miter cut, or notched and bent, to conceal stringers.
Step by Step installation Guide for Rail Posts:
Secure rail posts to the sub-structure for maximum security. DO NOT anchor posts to the decking surface. The following procedures will produce strong and safe deck railing.
Step 1. Anchor 4 x 4 rail posts to the interior of rim joists using lag or carriage bolts
Box the interior side of the anchor post.
Step 2. Notch AURORA Deck boards to fit around the rail posts
The notch should be ½" wider than the rail post in every direction. The notch for a 4 x 4 rail post should be 4½" wide H the required notch depth+½ ".(see Figure 12).
Step 3. Slide the deck board around the rail post and exposed anchor biscuits
Step 4. Use anchor biscuits to secure deck boards to the sub-structure
Step 5. Oversleeve rail posts with vinyl and finish with post caps and post skirts
Step by Step installation Guide for Covering Concrete Patios & Porches:
The AURORA Decking System may be used to cover concrete patios and porches. The surface of an AURORA Decking System used to cover a patio or porch will be approximately 3 inches above the surface of the underlying concrete.
Step 1. Anchor 2" Í 2" pressure treated wood sleepers to the concrete surface using hammer anchors or masonry screws
The sleepers perform a similar function to elevated deck joists and should be spaced 16" on center. If using masonry screws, countersink the screws flush with the top of the sleepers(see Figure 13).
Step 2. Install starter channel and decking as described in the step-by-step installation instructions
Secure anchors by driving 1" deck screws through the anchor biscuit slots into the sleepers. Do not secure anchor biscuits directly to concrete.
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